Roof or Facade Panel Having a Solar Panel

ABSTRACT

A roof or façade panel with at least one surface panel that can be fastened to buildings, wherein the surface panel is foamed directly with a carrier layer of foamed plastic, and wherein the surface panel comprises a solar panel.

The present invention relates to a roof or façade panel having a surfacepanel that is directly foamed with a support layer from foamed syntheticmaterial, and a process for production thereof and a constructionelement comprising the roof or façade panel.

According to the prior art, relatively thick panels, for example ofgranite, marble, stone, steel, metal, are usually produced for façadepanels. Sufficient thickness for these panels is necessary in that boresare produced in these panels using complex processes and the attachmentelements for attaching the panels to the building are subsequentlydisposed in these bores.

Since sufficient thickness for the façade panels is essential, knownfaçade panels have considerable weight per square meter. Known façadepanels are thus also only small in format since otherwise transportationand especially attachment to the building, i.e. mounting, would be toodifficult and troublesome.

Drilling the façade panels in order to fit the attachment elements isalso associated with a considerable risk since the panel can easilyfracture if care is not taken.

Façade panels and floor panels are also known from the prior art,wherein a surface layer is directly foamed with a support layer. Thissurface layer is of granite, marble, stone, ceramic or metal and is toconstitute the outer façade of the building or a floor covering.

However, roof panels with a surface layer directly foamed on a supportlayer are not known from the prior art.

Furthermore, in accordance with the prior art it is possiblesubsequently to attach solar or photovoltaic panels to a building.

Solar or photovoltaic panels are further understood to be a solarmodule, a photovoltaic module or a solar generator. These convertsunlight directly into electrical energy. A solar panel or moduleessentially comprises—starting on the side facing the sun—a pane ofglass, a transparent synthetic material layer, into which themonocrystalline or polycrystalline solar cells are embedded, wherein thesolar cells are electrically connected to each other by so-called solderstrips, rear-side lamination which has a weather-proof syntheticmaterial composite film, a connection socket and a connection terminaland an (aluminum profile) frame. Of particularly critical importance fora solar panel are a transparent, radiation-resistant and weather-proofcovering, protection of the solar cell against mechanical influences,protection of the components, in particular of the solar cells andelectrical connections against moisture, also robust electricalconnections, sufficient contact protection of the electricallyconductive components, also sufficient cooling of the solar cells, andhandling and attachment capabilities.

In particular, the cooling of solar modules is a decisive factor forhigh-level, consistent performance. For example, when using solarmodules in particularly hot areas the surface temperatures of the solarmodules can reach over 400° C., which can lead to a drop in performanceof more than 40%. The cooling of solar modules can thus have aconsiderable influence on the efficiency thereof. However, not only iscooling critical in and of itself but also in particular keeping thetemperature constant in order to achieve truly efficient use of themodule.

Solar cells are currently usually produced from semi-conductormaterials, predominantly silicon. As already mentioned, thesesemi-conductor solar cells are connected to large solar modules in orderto generate energy. For electrical connection purposes the cells areconnected in series to conductive tracks, i.e. the previously mentionedsolder strips on the front and rear side (so-called front and rear sidecontact), whereby the voltage of the individual cells is combined andthinner wires can be used than in the case of a parallel circuit.

Furthermore, in order now to attach solar or photovoltaic panels to abuilding in accordance with the said prior art these panels aresubsequently attached for this purpose in a known manner to the façadeor façade panels or to the roof or roof panels. To this end, attachmentelements are additionally attached to the solar panels in order to beable to connect them to the façade or the roof of a building. Thisrequires additional work and consequently also leads to higher costs.Moreover, there is a danger of damaging the solar panels by reason of,or during the attachment of separate attachment elements. Furthermore,the electrical connections must be reliably protected against moistureor even contact. In addition, an additional, adequate cooling means mustbe attached to the solar panel.

The object of the present invention is therefore a novel roof or façadepanel with a solar panel, which can be produced and mounted simply andsecurely.

In accordance with the invention this is protected by the features ofthe independent claims. The dependent claims develop the central idea ofthe invention in a particularly advantageous manner.

In accordance with the invention the roof or façade panel has at leastone surface panel that can be attached to buildings. The surface panelis directly foamed with a support layer from foamed synthetic material.The surface panel has a solar panel.

The support layer is advantageously foamed with an under layer on itsside opposite the surface panel, wherein the under layer is preferablyformed from a fire-retarding material such as calcium sulfate.

The support layer is advantageously a foamed rigid or rigid integralpolyurethane foam.

In a particularly advantageous manner, suspension or mounting means forattachment of the roof or façade panel to the building, metal gratings,tongue and groove elements, pipes, electronic components and/or othercomponents or elements are foamed in the support layer.

The pipes are preferably connected to the pipe system of a heatingarrangement, for example floor heating, and/or of a hot water supply,either directly or indirectly via heat exchangers.

In a particularly preferred embodiment the pipes have cooling coils.

Furthermore, a preferred process for producing the roof or façade panelsin accordance with the invention is described.

In a particularly preferred embodiment a special application of the roofor façade panels as a construction element, i.e. as an outer shell orroof covering of a building is described in claims 14 to 18.

The roof or façade panel described herein in accordance with theinvention has at least one surface panel which is directly foamed with asupport layer from foamed synthetic material, wherein the surface panelhas a solar panel. The solar panel can therefore be attached directly toa building as a complete roof or façade panel. In this way thesubsequent attachment of solar panels to the façade or to the roof of abuilding is avoided as they are directly integrated into the roof orfaçade panel. The roof/façade panel, insulation and solar cell aretherefore unified to form a single component. This integration of thesolar panel considerably reduces mounting time. The roof or façade panelcan therefore be attached directly to structural elements of a building,for example laid directly on the roof battens or attached to furtherparts of a static building construction of a building such as beams orreinforced concrete columns. In this way, for instance, it is possiblealso to save on the additional covering of a roof, for example with rooftiles, or the erection of an external façade since the panel can be usedas a complete roof or façade element. It is therefore possible to saveon the whole substructure of a roof or of a façade.

Since the panels have a particularly planar surface with no substantialimpact surface, for example with respect to wind, the roof or façadepanels in accordance with the invention are much less susceptible tosuch environmental influences in comparison to roofs covered with tilesor the like or solar panels subsequently attached to the roof or façade.For example, in the case of a storm, the risk of damage to the roof orfaçade construction and also the risk to passers-by from falling roof orfaçade elements (for example tiles) are therefore considerably reduced.

Furthermore, the panel in accordance with the invention is extremelythin and light in comparison to a roof or façade with a subsequentlyattached solar panel, whereby it is additionally possible to achieve aconsiderable weight saving compared with a conventional roof or façade.

In addition it is possible in a simple manner to foam together differentsurface panels to form a larger roof or façade element, whereby it ispossible to avoid additional effort required during mounting to alignthe surface panels on the roof or on the façade. The effort involved inmounting as a whole is therefore reduced by a multiple of the mountingeffort conventionally required for roofs or façades.

By foaming-in the solar panel on the back, protection of the rear of thesolar cells against mechanical influences and protection of the rearcontacts against moisture is also achieved at the same time. Moreover,the electrical connections can be designed less robustly, provided theyare embedded in the support layer. Similarly, owing to the supportlayer, sufficient rear protection of the electrically conductivecomponents against contact is also provided at the same time so that itis possible to dispense with further protection at this location.

For example, in the case of renovation of an old building it is possiblein a single operation to improve the insulation of the roof or of thefaçade and at the same time to construct and attach solar cells or solarmodules in a simple manner.

The support layer is also preferably foamed with an under layer on itsside opposite the surface panel. By means of this additional layer theroof or façade element can fulfil further requirements such as certainfire-protection requirements. To this end, the under layer is formed ina particularly advantageous manner as a calcium sulfate plate which hasa particularly fire-retarding effect. Other fire-retarding materials arealso feasible.

Furthermore, rigid or rigid integral polyurethane foam is alsopreferably proposed as a foamable synthetic material. This syntheticmaterial is principally characterized by its great strength in thefoamed region, its good heat-insulating properties and its rapid bondingand hardening capability. This foam is also watertight, which means thatthe solar cells and the electrical contacts do not require additionalprotection against moisture, for example by a further protective layer,at least on the rear of the solar panel. The penetration of water, forexample rain water, can thereby easily be prevented. Owing to its lowdelta T, condensation of, for example, water in the system can also beavoided so that the formation of mold or moss, which occurs for examplein the case of subsequently attached solar panels on a roof or façade,can be effectively avoided

Suspension or mounting means for attachment of the roof or façade panelto the building, metal gratings, tongue and groove elements, pipes,electronic components and/or other components are preferably foamed inthe support layer.

Incorporation of attachment elements such as hooks, threads, etc, intothe foam structure by means of a single fully automatic process duringfoaming leads to a tough, high-strength bond after the foam hashardened, which connects the surface panel to the foamed syntheticmaterial and at the same time encloses the attachment elements. Thesensitive solar panels as surface panels with the brittle solar cellsthus do not have to be provided with additional holding elements ordrilled holes in order to be attached, nor do they need to be drilledthemselves or in their frames since the attachment elements are alreadyanchored in the support layer. All the forces acting on the roof orfaçade panel are therefore shifted into the support layer. The risk ofdamage or breakage of a solar panel is therefore minimised and thehandling and attachment means which are usually attached directly to thesolar panels can be omitted.

The use of polyurethane foam as the support layer means that this canalso be used for heat insulation. The support layer therefore not onlyserves for non-positive breakage prevention of the solar panel but alsoto receive the attachment elements and also as insulation against heatand cold.

Metal gratings can also preferably be foamed into the support layer andincrease the strength of the support layer and can additionally serve toreinforce the support layer of particularly heavy roof or façade panels.

Tongue and groove elements are advantageously foamed into the supportlayer and can facilitate the installation of the roof or façade paneland ensure that the panels hold together in a stable manner.

In a particularly preferred embodiment pipes are foamed into the supportlayer. The pipes have cooling coils or cooling agent coils in oneparticularly preferred embodiment. In this way the cooling devicenecessary to, and adequate for, solar cells is integrated directly andsimply into the support layer and therefore does not have to beadditionally integrated or attached. By the integrated discharge of heatthe efficiency of the solar panel can therefore be increasedconsiderably more.

The heat-carrying agent circulating in the cooling coils can alsopreferably be used via an attached heat exchanger, for example for thesupply of hot water. For this purpose the cooling coils can be connecteddirectly to a hot water supply installation or to a heatinginstallation.

It is also feasible for the heated cooling agent fluid also to be usedalternatively or additionally via turbines to produce electricity,whereby the efficiency of the solar panels can be increased stillfurther. The cooling of the solar panels can therefore be exploited innumerous ways for heating, for hot water supply or even for theproduction of electricity.

Alternatively, the possibility exists of applying a further translucentlayer to the surface layer for cooling purposes. This layer, for exampleof glass, contains channels such as pipes, which in a particularlypreferred embodiment have cooling coils or cooling agent coils. Thepipes can be attached in the same way directly to the additional layer.Heat exchangers which discharge heat and are connected to the pipes canadditionally be foamed into the support layer.

It is also feasible instead of the pipes to use an aeration system inthe translucent layer. The thermal arising therein can then be rendereduseable with a heat exchanger in the manner described above.

In a very general way it is possible to foam a wide range of componentsand elements into the support layer. This principally also includeselectronic components of any type since, owing to their small size, theycan very easily be introduced into foaming molds.

The method in accordance with claims 12 and 13 is particularlycharacterized in that it is totally unaffected by the solar panels beingof different thicknesses. Even if a solar panel has portions ofnon-uniform thicknesses, for example at the connection points ofindividual solar cells or on the rear contacts of a solar cells the roofor façade panels produced by means of the process in accordance with theinvention always have a constant overall thickness since the thicknessof the rigid or rigid integral polyurethane foam can vary. Roof orfaçade elements which appertain to a roof or façade of a building canthereby all be produced with an absolutely identical thickness.

Further features, advantages and properties of the invention will now beexplained with the aid of exemplified embodiments and the figures of theaccompanying drawings.

FIG. 1 shows a roof or façade element in accordance with the invention,and

FIG. 2 shows a construction element in accordance with the inventionwith cooling coils foamed in.

FIG. 1 shows a roof or façade element in accordance with the inventionhaving at least one surface panel 2 foamed directly with a support layer1. The surface panel 2 comprises a solar panel 3.

Foaming a solar panel 3 with a support layer 1 as a roof or façade panelmeans that the solar panel does not additionally have to be mounted ontothe roof or façade of a building. The solar module itself therefore nolonger has to be fitted with its own handling and attachment means.Furthermore, at the same time the rear of the solar cells is at leastprotected against mechanical influences and the rear contacts are atleast protected against moisture and other influences. Moreover, if theelectrical connections are also embedded into the support layer they canalso be less robust. Since the electrically conductive components arefoamed into the support layer at least on the rear of the solar module,sufficient contact protection is also provided at the same time at thatlocation so that it is possible to dispense with further protection atthese points.

The electrical connections of the solar panels 3 for carrying away thegenerated electricity can be led out of the foamed synthetic materialmass during the foaming process so that the electricity can easily bedischarged from the solar modules and, for example, stored or useddirectly by consumers. A connection socket with a diode and/or theconnection terminal of the solar panel 3 are preferably disposed andfoamed-in in such a way that they are accessible from the inside of theroof or façade panel. The connections of the solar panels 3 aretherefore easily accessible and are securely protected from the weatheron the inside of the panel.

It is also feasible for the connection socket and/or the connectionterminal, additionally or alternatively, to be accessible afterfoaming-in on at least one side on which the roof or façade panel is tobe connected to a further panel. These connection elements arepreferably designed as a plug connection. It is therefore possible toconnect in series a plurality of solar panels on a plurality of roof orfaçade panels simply and directly during attachment of the roof orfaçade panel, whereby mounting of the panels is further simplified.

The support layer 1 is a foamed synthetic material, advantageously afoamed rigid or rigid integral polyurethane foam. This syntheticmaterial is characterized in particular by its high level of strength,its good heat-insulation properties and its rapid bonding and hardeningcapability. The support layer 1 serves both for non-positivebreakage-prevention of the solar panel 3 and also as thermal insulation,i.e. as insulation against heat and cold. The rigid or rigid integralpolyurethane foam is also watertight so that the solar cells and theelectrical contacts do not have to be additionally protected againstmoisture at least on the rear of the solar panel 3, for example, by afurther protective layer. Similarly, condensation in the system isprevented owing to the low delta T so that the formation of mold or mosscan be effectively prevented. It is also feasible for other foamablematerials to be used as the support layer.

Components or elements are preferably foamed in the support layer 1.These can be, for example, suspension or mounting means for attachmentof the roof or façade panel to the building, metal gratings, tongue andgroove elements, pipes, heat exchangers, electronic components and/orother components or elements. In addition to its properties ofpreventing breakage and of heat insulation the support layer thereforealso serves to receive components and elements.

Foaming metal gratings, for example steel mesh gratings such asconstruction steel gratings, into the support layer 1 of the roof orfaçade element can increase the strength of the support layer 1. In thecase of particularly heavy roof or façade panels a metal grating of thistype can thus also serve as reinforcement of the support layer 1.

In a preferred embodiment, for example, tongue and groove elements arefoamed into the support layer. For this purpose wire meshes or meshtubes of HPL (“high pressure laminate”) material strips are preferablyfoamed in as tongue and groove elements which are provided with holes inorder to achieve a non-positive connection to the (polyurethane) foam ofthe support layer 1. The wire mesh or the HPL grating then serves toincrease the load-bearing capacity of the roof or façade panel. Thetongue and groove element facilitates the installation of the roof orfaçade panel and ensures that mutually connected panels hold together ina stable manner.

Pipes preferably foamed into the support layer 1 preferably have coolingcoils or cooling agent coils 8 as shown in FIG. 2. The cooling coils 8foamed into the support layer 1 preferably have a heat-carrying agentflowing through them when the roof or façade panels are in the mountedstate. In this way the cooling which is necessary to, and adequate for,solar cells is integrated directly and simply in the support layer. Itis therefore possible to dispense with additional attachment of acooling means, which makes mounting easier and also leads to savings incosts and materials. In a preferred embodiment the cooling coils 8 areattached, preferably welded, to a heat-conducting plate 9 preferablymade from a highly heat-conductive material. The heat-conducting plate 9is in turn preferably disposed or attached on the rear to the solarpanel 3 and therefore ensures uniform heat distribution of the heatdischarged from the solar panel 3. The heat can then simply betransferred from the solar panel 3 via the heat-conducting plate 9 tothe cooling coils 8 and therefore to the heat-carrying agent in thecooling coils 8 and can be discharged.

The heat transferred from the roof or façade panels via the solar panel3 to the heat-carrying agent in the cooling coils 8 can furthermore betransferred directly or indirectly preferably via heat exchangers 10into or onto the circuit 11, 11′ of a (floor) heating system 12 or intoor onto the water circuit for supplying hot water (not shown). FIG. 2illustrates, for example, indirect heat transfer by means of heatexchanger 10, wherein the circuit 11 shows the cooling agent circuit ofthe solar panel 3, and the circuit 11 illustrates the utility circuit,in this case the heating circuit. The circuits 11, 11′ are only shownschematically. The broken lines are intended to indicate that thecooling coils 8 are integrated into the cooling agent circuit 11.

The cooling coils 8 therefore ensure improved heat discharge through theroof or façade sandwich panels, whereby on the one hand the degree ofefficiency of the solar cells is increased. On the other hand, differentdegrees of expansion owing to stresses which arise in the solar orphotovoltaic panels 3 by reason of temperature swings can in this wayreliably be reduced. In addition, the heated cooling agent from thecooling coils 8 can be further used for hot water supply or for heatexchangers.

The cooling agent fluid heated after the cooling process can also beused to produce electricity by means of turbines. In this way theefficiency of the solar panels can be considerably increased further.The cooling arrangement of the solar panels 3 can therefore be used inmany alternative ways, for example for heating, for hot water supply oreven to produce more electricity.

In order to simplify the cooling system or connection thereof, thecooling coils 8 can be foamed into the support layer 1 in such a waythat at least one end of the cooling coils 8 in each case is disposed sothat it leads to the edge of the roof or façade panel and is accessiblefrom outside. The ends of the cooling coils 8 are preferably led to atleast one side of the roof or façade panel on which this is to beconnected to a further one so that the cooling coils 8 of a roof orfaçade panel can easily be connected, during mounting, to those of afurther panel. For this purpose the pipes or cooling coils 8 areconnected at the corresponding connection points preferably withconnection elements, for example screw or plug connections, in order toconsiderably simplify further the mounting of roof or façade panelswhich are provided with solar panels 3 and have an integrated coolingsystem.

In a further embodiment the pipes, preferably cooling coils or coolingagent coils 14, are located in or immediately adjoining an additionallayer 13 as shown in FIG. 1. This preferably translucent layer 13, forexample of glass, is attached to the solar or photovoltaic panel 3.

The heat transferred from the roof or façade panels via the solar panel3 to the heat-carrying agent in the cooling coils 14 can also berendered usable as described above, directly or indirectly preferablyvia the heat exchanger 15 foamed in the support layer. FIG. 1 shows byway of example an indirect heat transfer by means of heat exchanger 15.The broken lines are intended to indicate that the cooling coils 14 areintegrated into the cooling agent circuit 16.

It is also possible to use an aeration system in the translucent layerinstead of the pipes. The thermal arising therein can then be renderedusable by the heat exchanger in the manner described above.

Furthermore, other components and elements can also be foamed into thesupport layer 1 as desired. In a particularly advantageous embodiment,electronic components are foamed into the support layer 1. Theconnection lines can be led out of the foamed synthetic material masseven during the foaming process so that connection of these componentscan easily be effected after the respective panel has been produced. Itis also possible to provide corresponding connection elements in thesupport layer 1 which then, like the solar panel 3, are easilyaccessible, for example, from the inside of the roof or façade panel.

A wide range of possibilities exist with respect to the electroniccomponents, in particular in domestic technology. Thus, for example,light or temperature sensors which control automatic curtains, blinds,air conditioning or heating can be foamed in. Since the rigidpolyurethane foam is also watertight, these sensors do not need to beadditionally protected against moisture.

It is also possible to integrate radio antennas, for example forwireless networks and wireless internet access but also for mobiletelephony, into the foamed synthetic material layer 1. The radioantennas would then be integrated in the roof or in the house façade andwould not impair the visual appearance of the roof or façade.Furthermore, the electricity from the solar panels can be used directlyfor the components integrated in the support in order thereby toimprove, for example, the reception or transmission strength or quality.

The support layer 1 is also preferably foamed with an under layer 4 onits side opposite the surface panel 2 or the solar panel 3. This lowerlayer 4 serves, for example, for visual purposes or other specificrequirements, such as preferably fire-protection requirements. The underlayer 4 is preferably formed as a calcium sulfate plate which hasspecial fire-retarding properties. However, other layer materials withadvantageous properties for roof or façade panels are also feasible.

In a further embodiment the layer 4 can also be foamed with the supportlayer 1, for example, on at least one of the lateral outer regionsthereof in order to exploit its properties in these regions as well (cf.FIG. 2). In particularly preferred manner, a plate, preferably a calciumsulfate plate, is preferably disposed on each side of the support layer1 with the exception of the front side.

In order to lead or render accessible any electrical connections orconnection elements through the under layer 4, access points, forexample in the form of holes, can be provided in the under layer 4 atdefined positions. These are preferably selectively closable with acover, for example, by means of a simple screw or plug connection. Thecover is preferably made of the same material as the under layer 4.

By integration of the solar panel 3 into the roof or façade panel, thesolar panel 3 can in this way be attached directly to a building as acomplete roof or façade panel, which makes subsequent attachment ofsolar panels 3 to the roof or to the façade of a building superfluous.Therefore a roof/façade panel with insulation and a solar cell andpossible further properties, for example fire-protection properties, canbe united to form a single component. In so doing, it is thus possibleto make savings on the entire substructure of a roof or façade, whichconsiderably reduces both production costs and also mounting time of aroof or façade construction fitted with solar cells.

The solar panels themselves can also be formed in a much more simple andcost-effective manner since it is possible to dispense with additionalprotection means such as protection against mechanical influences,moisture and contact at least on the rear of the solar panel, and alsoto dispense with additional cooling means and further handling andattachment means on the solar panels themselves.

The properties and functionality of the roof or façade panel inaccordance with the invention can be considerably improved further inthat any other desired components and elements can be foamed into thesupport layer 1 in order, for example, to simplify the attachment ofsuspension and mounting elements, to improve the discharge of heat andto exploit the discharged heat or to integrate electrical components ina concealed manner.

A production process for a roof or façade panel in accordance with theinvention is described hereinunder.

The surface panel 2, which comprises the solar panel 3, is first placedinto a mold which is then closed. Two liquid components are theninjected into the mold, which react with each other and foam. Afterfoaming, the synthetic material, preferably a polyurethane syntheticmaterial, hardens automatically. The resulting connection to the solarpanel 3 is principally characterized by its very high level of strength.

The process in accordance with the invention permits the use of solarpanels 3 with an insulation layer as a complete unit for a roof coveringor façade. By reason of its small thickness and its low weight, since,for example, it is possible to dispense entirely with further outermaterials such as roof tiles or façade panels, a major part of thematerial costs, such as for example expensive surface materials, issaved and mounting is considerably facilitated. Furthermore,irregularities in the solar panels, for example at the connection pointsbetween individual solar cells or on the rear contacts of a solar cell,do not affect the finished roof or façade panel since, after foamingwith the support layer 1, each roof or façade panel produced in thisway, preferably in the same or an identical mold, always has the set,uniform, constant overall thickness. Varying thicknesses in a solarpanel 3 are therefore automatically corrected in that the support layer1 is formed thinner at the corresponding points depending on theenclosing mold.

By positioning attachment elements such as hooks, threads etc in themold, these can also be foamed into the support layer 1. Byincorporating attachment elements into the foam structure by means of asingle fully automatic process during foaming, a tough, high-strengthconnection is produced after the foam hardens, which connects the solarpanels 3 to the foamed synthetic material and at the same time receivesthe attachment elements. The surface panels 2 or the solar panels 3 thusdo not need to be provided with additional holding elements or drilledholes in order to be attached, nor do they need to be drilled themselvesor in their frames since the attachment elements are already anchored inthe support layer. The loading of the whole roof or façade elementtherefore takes place in the stable support layer 1 and not in thesurface panel 2, i.e. the solar panel 3, whereby the risk of damaging orbreaking a solar panel 3 is minimised.

The roof or façade panels in accordance with the invention can on theone hand be used as panels which are aerated from behind (FIG. 1). Onthe other hand, however, it is preferably also possible to attach theroof or façade panels directly to existing roof battens or existingmasonry. Therefore, for example for the purposes of renovating an oldbuilding or in new builds, these panels can serve as an actual roofcovering or outer wall (FIG. 2) and at the same time can consequentlynaturally also serve as insulation and as an internal wall or internalceiling, i.e. as a so-called construction element. The insulation of theroof or the façade is therefore improved and at the same time solarcells are attached in a single operation. In the case of theconstruction element the support layer 1 is formed substantially thicker(preferably ca. 100-200 mm of rigid or rigid integral polyurethane foam)than in the case of use as roof or façade panels aerated from the rear(preferably ca. 20-50 mm rigid or rigid integral polyurethane foam).

As a construction element the roof or façade panel is additionallyfoamed with the under layer or inner layer 4 on the inside of thesupport layer 1, i.e. on the [side] opposite the surface layer 2. Theunder layer 4 is advantageously formed as a fire-retarding calciumsulfate plate and also preferably has a thickness of ca. 25-45 mm. Theunder layer 4 preferably has a smooth surface and can be suitable forwallpapering over, for which reason it is particularly suitable as aninternal wall or internal ceiling.

The size of the roof or façade element or construction element alsodiffer depending on the function of the roof or façade element, i.e. onwhether the roof or façade element is to be suspended as a roof orfaçade element which is aerated from the rear on an existing roof or anexisting external wall or on whether it is to be used as a constructionelement. A construction element preferably has a size of ca. 2-3 m×1.5m, whereas a roof or façade element for use as a roof or façade elementwhich is aerated from the rear is preferably produced substantiallysmaller, for example in the range of 120 cm×60 cm or 120 cm×120 cm. Withthe process it is also possible in a particularly simple manner to foama plurality of surface panels, i.e. solar panels, together to form alarger roof or façade element, whereby additional mounting effortimposed by alignment of the surface panels on the roof or on the façadecan be avoided. Since savings can be made on the whole substructure, theeffort involved in mounting is therefore also reduced by a multiple ofthe mounting effort conventionally required for roofs or façades.

Furthermore, the stability of the roof or façade panels increases thethicker the support layer 1 is. It is therefore possible as thethickness of the panels increases to attach the roof rafters at agreater distance from each other and therefore also to save costs in theactual construction of the house. These panels are then also suitable inparticular for larger expanses such as, for example, factory or workspremises. Using a thick support layer 1 all attachment parts, such asscrews or other anchoring means, can additionally be mounted withsufficient stability in this roof or façade construction.

The construction element is preferably attached directly to structuralelements 5 of a building i.e. for example, the roof battens or supportsor reinforced concrete columns of a static building construction. Tothis end it is possible to provide a recess 6. Attachment is effected,for example, by means of a metal bracket 7 which is connected to thestructural elements 5. All feasible types of mounting such as, forexample, welding, screwing, bonding or suspension attachments arepossible. The overall thickness of the construction element is forexample 35 cm (8 cm calcium sulfate panel 3, 1 cm surface panel 2, i.e.the solar panels 3, and 26 cm rigid or rigid integral polyurethane foamlayer 1), wherein the thickness of the respective layers can varydepending on the area of usage and the materials used. The panel inaccordance with the invention is extremely thin and light in comparisonto a roof or a façade with a subsequently attached solar panel, wherebyit is possible to achieve a great weight saving with respect to aconventional roof or façade, which in turn has the overall effect ofmaking these panels easier and better to handle.

In the case of roof or façade panels in accordance with the inventionprovided with a cooling means it is possible to mount these panelscloser together because they expand less, and therefore to reduce theexpansion gaps. The lower level of expansion also means that wear on theroof or façade panels is reduced, whereby the service life thereof is inturn increased.

Provision is preferably made to fill the gaps between the panels withconventional expanding foam or similar suitable materials once the roofor façade panels have been laid. In this way any penetration, forexample, of rain water between the panels is also prevented. When theroof or façade panels can be mounted closer to each other owing to thecooling arrangement in accordance with the invention, it is alsopossible in this way to save on expanding foam owing to the narrowerexpansion gaps.

The roof or façade panels form, in particular also in the mounted state,a particularly uniform surface over all panels of a compositearrangement and therefore offer a clearly smaller impact surface, forexample with respect to wind for instance, than tiles or similarlycovered roofs or also solar panels subsequently attached to the roof orfaçade. The likelihood of damage to the roof or façade construction, forexample during/by reason of a storm is therefore clearly reduced.

With the roof or façade panels a large number of visual effects can alsobe achieved on the surface of the solar cells, for example, by means ofa special polishing of the glass or by using dye-sensitised solar cells.Dye-sensitised solar cells use an organic dye for conversion of lightinto electrical energy, wherein different dyes and degrees oftransparency permit a variety of design possibilities. For example, asimulated roof or façade (for example, tiled roof or slate roof effect)can be achieved by the said grinding of the glass or also the dyes. Thisis then particularly advantageous if, for example, in spite of buildingregulations (for example for the protection of historic buildings), acertain roof structure or façade structure is required withoutdispensing with solar energy. It is also possible by the same means toblend in the solar panels in such a way that disruption of thesurroundings owing to the reflected sunlight can be avoided.

The invention is not limited to the limitations described above. Anytype of foamable materials for the support layer and all materials whichare suitable for the under layer are feasible. All feasible componentsor elements can also be foamed into the said support layer. Furthermore,the panels can be attached to all parts and areas of a building.

REFERENCE LIST

-   -   (1) Support layer    -   (2) Surface layer    -   (3) Solar panel    -   (4) Under layer    -   (5) Structural element of a building    -   (6) Recess    -   (7) Metal bracket    -   (8) Cooling (agent) coils    -   (9) Heat-conducting plate    -   (10) Heat exchanger    -   (11) Cooling media circuit    -   (11) Utility circuit    -   (12) Heating    -   (13) Translucent layer    -   (14) Cooling (agent) coils    -   (15) Heat exchanger    -   (16) Cooling media circuit

1. Roof or façade panel comprising at least one surface panel that canbe attached to buildings, wherein the surface panel is directly foamedwith a support layer of foamed synthetic material, and wherein thesurface panel comprises a solar panel.
 2. Roof or façade panel asclaimed in claim 1, wherein on a side opposite the surface panel thesupport layer is foamed with an under layer.
 3. Roof or façade panel asclaimed in claim 2, wherein the under layer is formed from calciumsulfate or another fire-retarding material.
 4. Roof or façade panel asclaimed in claim 1, wherein a further, translucent layer is attached tothe surface panel.
 5. Roof or façade panel as claimed in claim 1,wherein the support layer is foamed rigid polyurethane foam or rigidintegral polyurethane foam.
 6. Roof or façade panel as claimed in claim1, wherein suspension or mounting means for attaching the roof or façadepanel to a building are foamed in the support layer.
 7. Roof or façadepanel as claimed in claim 1, wherein a metal grating is foamed in thesupport layer.
 8. Roof or façade panel as claimed in claim 1, whereintongue and groove elements are foamed in the support layer.
 9. Roof orfaçade panel as claimed in claim 1, wherein pipes are foamed in thesupport layer.
 10. Roof or façade panel as claimed in claim 9, whereinthe pipes are located in a translucent layer or are directly attachedthereto.
 11. Roof or façade panel as claimed in claim 9, wherein thepipes are connected to a pipe system of floor heating either directly orindirectly via heat exchangers.
 12. Roof or façade panel as claimed inclaim 9, wherein the pipes are connected to a pipe system of a hot watersupply either directly or indirectly via heat exchangers.
 13. Roof orfaçade panel as claimed in claim 9, wherein the pipes comprise coolingcoils.
 14. Roof or façade panel as claimed in claim 4, wherein thetranslucent layer comprises an aeration system that leads to a coolingmeans for the solar panel and renders the thermal which arises usable byheat exchangers.
 15. Roof or façade panel as claimed in claim 9, whereinheat exchangers are foamed into the support layer.
 16. Roof or façadepanel as claimed in claim 1, wherein electronic components are foamed inthe support layer.
 17. Process for producing a roof or façade panel asclaimed in claim 1, comprising introducing a surface panel, comprising asolar panel into a mold and then injecting at least two liquidcomponents into the mold, which components foam upon contact to form arigid or rigid integral foam.
 18. Process as claimed in claim 17,comprising introducing roof or façade panels that belong together andare produced for the same building into the same mold or an identicalmold and maintaining the thickness of the mold constant regardless ofthe thickness of the solar panel.
 19. Construction element comprising aroof or façade panel as claimed in claim 1, wherein the constructionelement is attached directly to structural elements of a building. 20.Construction element as claimed in claim 19, wherein the constructionelement has a recess that can be attached to two adjacent sides of thestructural elements.
 21. Construction element as claimed in claim 20,wherein the recess is lined with a metal bracket.
 22. Constructionfaçade element as claimed in claim 19, wherein the structural elementscomprise supports or roof battens of the building.
 23. Constructionfaçade element as claimed in claim 19, wherein a calcium sulfate plateis disposed on each side of the element except a front side.
 24. Processfor producing a roof or façade panel as claimed in claim 17, whereinsaid liquid components comprise polyol and isocyanate.